Actually it wasn't the shop manual that I saw the tank trim removal, it was Service Bulletin M-1152. Here's the description without drawings or check this site Bert found and look at Bulletin M-1152.
M-1152 1 of 3
2004 SPORTSTER FUEL TANK CONSOLE
As a running change, the XL Custom fuel tank console
assembly has been redesigned to minimize the potential for
console fitment complaints and seat damage. This bulletin
describes how to identify these problems and replace consoles
on affected vehicles.
All 2004 XL 1200 Custom models produced before 2/17/04.
Required Dealer Action
If any of the following conditions exist, follow the instructions
below to replace the console assembly:
If the seat has been damaged by the pin and clip assembly
attached to the rear end of the console.
If the metal console is loose from the plastic liner.
If the metal console rattles.
If there are exposed sharp edges on the metal console.
When the condition(s) exist which require console replacement,
order the redesigned console, Part No. 71276-04A,
through normal parts order process. You will be billed accordingly
and reimbursed when you file a claim. See Credit Procedure.
Replace seat if it has been cut or torn. If the integrity of the
seat has not been compromised and damage is in a nonvisible
area, seat is deemed acceptable and is not to be
Special Tools Needed
Console Alignment Ring HD-47114.
Temporary use of a smaller diameter fuel filler cap (H-D
Part Number 61272-92B). This is the original equipment
cap found on 2004 or later XL883 and XL1200R Sportsters,
as well as many other Harley-Davidson models.
Approximately 18 in. (0.46 M) fishing line (or string) to
aid in removing the existing console.
1. Refer to the Sportster Models Service Manual and follow
the instructions given to remove the seat. Retain all seat
Stop the engine when refueling or servicing the fuel system.
Do not smoke or allow open flame or sparks near
gasoline. Gasoline is extremely flammable and highly
explosive, which could result in death or serious injury.
2. See Figure 1. Remove the original fuel filler cap (2) from
the fuel tank (1) and set it aside. Obtain a small diameter
Harley-Davidson fuel filler cap (5) and screw it into the
fuel filler opening.
Figure 1. Console Installation
1. Fuel tank
2. Original equipment fuel filler cap
3. Fuel tank console
4. Console alignment ring (Part No. HD-47114)
5. Small diameter fuel filler cap
M-1152 April 23, 2004
In the interest of preserving customer safety and satisfaction, always check for outstanding recalls whenever any motorcycle is brought into your
dealership for either maintenance or service.
©2004 HARLEY-DAVIDSON MOTOR COMPANY
M-1152 2 of 3
3. See Figure 2. Insert the fishing line (2) between the rear
of the fuel tank and the plastic liner (1) on the underside
of the original console.
Raise the ends of the fishing line away from the fuel tank to
avoid scuffing the tank finish.
4. Using a side-to-side “sawing” motion, work the fishing
line toward the front of the fuel tank to break the adhesive
bond between the console and the tank.
5. Carefully remove the console and liner from the fuel tank
and discard it.
Be careful not to scratch the paint on the fuel tank when
removing the adhesive.
To avoid damaging the fuel tank finish, do not use tools or
abrasive cleaners to remove the adhesive residue that
remains on the fuel tank surface. Try to stay within the area
that will be covered by the new console.
6. See Figure 3. To remove any adhesive residue remaining
on the fuel tank surface:
a. Carefully peel off as much adhesive as possible,
using your thumb and fingers only.
Observe warnings on labels of cleaning compounds.
Failure to follow warnings could result in death or serious
Use of cleaning compounds other than isopropyl alcohol
may damage fuel tank finish. Test in inconspicuous area.
b. Clean the top of the fuel tank with a mixture of 50%
to 70% isopropyl alcohol and 30% to 50% distilled
water or, if necessary, straight isopropyl alcohol.
c. Allow the fuel tank surface to dry thoroughly
1. See Figure 4. Measure and mark the centerline of the
fuel tank at the rear of the tank.
2. Obtain the
fuel tank console. Measure and mark the
centerline of the console at the rear of the panel.
3. See Figure 5. Place Console Alignment Ring (Part No.
HD-47114) over the fuel filler cap.
Figure 2. Removing Existing Console
Figure 3. Removing Adhesive Residue
Figure 4. Marking Fuel Tank Centerline
Figure 5. Placing Console Alignment Ring Tool
(Part No. HD-47114)
1. Original fuel tank console liner
2. Fishing line or string
M-1152 3 of 3
4. Peel the liner from the adhesive backing of the console.
5. Position the console over the fuel tank without touching
the adhesive to the tank surface. Center the large hole
over the console alignment ring tool, and align the mark
on the rear of the console with the mark made on the
rear of the fuel tank.
6. Slide the front of the console down over the console
alignment ring tool onto the fuel tank. Bring the rear of
the console down, keeping the marks aligned.
7. Press the console firmly against the top of the fuel tank
and hold pressure for 30 seconds. After releasing pressure,
avoid direct contact with the console for about 20
minutes, then remove the console alignment ring tool.
8. Remove the small-diameter fuel filler cap and install the
original fuel filler cap.
9. Refer to the Sportster Models Service Manual and follow
the instructions given to install the seat.
After installing seat, pull upward on front of seat to be
sure it is in locked position. While riding, a loose seat can
shift causing loss of control, which could result in death
or serious injury. (00070a)
10. Allow AT LEAST 24 hours after applying the console
before exposing the area to vigorous washing, strong
water spray or extreme weather. The adhesive bond will
increase to maximum strength after about 72 hours at
normal room temperatures.
For each vehicle requiring console replacement, complete a
regular warranty claim referencing Service Bulletin M-1152 in
the ‘Comments’ or ‘Note’ field of the claim. Fill in the rest of
the claim as follows:
Upon receipt and processing of the properly completed claim,
you will be credited the appropriate amount for parts and
labor. Be sure to destroy and properly dispose of all replaced
fuel tank consoles 60 days after receiving credit on the
This condition will be warranted while the vehicle is still under
factory warranty only.